Woven Patches

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Woven Patches

High-Density Precision Woven Patches & Insignia

At High Rated Patch, our custom woven patches are the professional choice for designs that require a balance of traditional textile texture and high-resolution detail. Unlike embroidered patches that use thicker threads stitched onto a base fabric, woven patches are created by weaving thin, high-tenacity threads together to form both the design and the patch structure simultaneously. This results in a sleek, low-profile finish with significantly higher detail clarity than standard embroidery.

Our woven products are engineered for brands that demand a clean, modern aesthetic without the bulk of traditional stitching. By utilizing high-warp density weaving technology, we provide a flat, smooth surface that allows for intricate lettering and complex patterns while maintaining the classic feel of a high-end fabric emblem.

High-Definition Woven Patches

The hallmark of our woven patches is the use of ultra-fine polyester threads. These threads are approximately 1/3 the thickness of standard embroidery yarn, allowing for a much tighter weave. This technical advantage enables the reproduction of small text (down to 2mm) and sharp geometric lines that would otherwise become blurred in an embroidered format. The result is a crisp, legible brand mark that is lightweight and highly flexible.

From fine text to complex artwork, our stitching delivers depth and clarity without compromising fabric integrity. Each patch is quality-checked to ensure strong stitch bonding, minimal thread breaks, and long-lasting performance, making it suitable for uniforms, branding, and everyday wear.

Smooth, Snag-Free Surface

Because the design is woven into the patch rather than on top of it, woven patches feature a 100% flat surface. This prevents snagging and thread-pulling, making them ideal for high-performance activewear, cycling jerseys, and premium headwear. Our industrial looms ensure consistent tension across every square inch, providing a patch that is resistant to warping and maintains its shape over the entire lifecycle of the garment.

Customization

Customize Your Patch

Multiple backing and border options to match your patch’s use and appearance.

Backing Options
Border Options

Sew-On Backing

A traditional, permanent method that ensures maximum durability for uniforms and heavy-duty apparel through direct stitching onto the garment fabric.

Iron-On Backing

A convenient and popular choice that allows you to apply patches easily using a standard heat press or household iron.

Adhesive Backing

A versatile, temporary solution perfect for events and short-term applications where patches need to be applied quickly without using heat.

Hook-and-Loop Backing

A two-part system designed for maximum versatility, allowing patches to be easily interchanged on tactical gear, uniforms, and specialized outerwear.

Peel-and-Stick Backing

An instant attachment method featuring a pressure-sensitive adhesive, ideal for one-time events, product launches, or temporary promotional branding needs.

Velcro Backing

A highly reliable, reusable backing that provides a secure grip while allowing for frequent repositioning on caps, bags, and professional uniforms.

Merrow Border

A classic, heavy-duty overlock stitch that creates a raised, rounded edge, providing a traditional finish ideal for standard shapes like circles, squares, and shields.

Heat-Cut Border

A precise finishing technique that uses heat to seal the edges of custom-shaped patches, effectively preventing fraying while maintaining a clean, sharp, and low-profile look.

Laser-Cut Border

An advanced manufacturing method using high-precision lasers to achieve intricate, complex shapes and internal cutouts that traditional cutting tools simply cannot replicate with such accuracy.

Stitched Border

A sleek and professional flat-stitch finish applied directly to the edge, perfect for thinner patches or designs requiring a modern, streamlined aesthetic on high-performance apparel.

Showcase

Recent Woven Patches Work

Browse our latest production to see the quality and expert craftsmanship we provide for brands and organizations worldwide.

FAQs

Have Any questions?

Find answers to the most common questions about woven patches, including their types, uses, and customization options.

Why should I choose woven patches over embroidered patches?

The primary reason to choose woven patches is the level of detail. Because woven threads are much thinner than embroidery threads, we can achieve much sharper resolution for small text and intricate logos. Additionally, woven patches are significantly thinner and more flexible, meaning they don't feel heavy or stiff on your clothing. If your logo has fine details or you want a modern, "retail-quality" look, woven is the superior choice.

Are woven patches as durable as embroidery?

Yes. In many cases, they are actually more durable. Because the design is part of the weave itself, there are no raised loops or thick stitches that can get caught on objects and pull out. Woven patches are highly resistant to abrasion and can withstand hundreds of industrial wash cycles without losing their clarity or color.

Can I get a 100% color match with woven patches?

We use a vast library of industrial polyester thread colors to match your brand's Pantone® references as closely as possible. Because we use high-density weaving, the color blending is much smoother than in embroidery, allowing us to represent your brand's color palette with high accuracy and vibrant consistency.

What is the smallest text size possible on a woven patch?

While traditional embroidery struggle with anything under 5mm, our woven technology can accurately render text as small as 2mm to 3mm depending on the font style. This makes woven patches the best option for website URLs, small slogans, or complex technical logos that must remain legible.

Are woven patches suitable for hats and beanies?

Absolutely. In fact, they are a favorite for headwear. Their thin, flexible nature allows them to conform to the curve of a hat or the stretch of a beanie without puckering or creating a "bump." They provide a very high-end, clean finish that mimics the branding found on major global streetwear and athletic brands.

Do woven patches have a "textured" feel?

Woven patches have a very smooth, almost "satin-like" feel compared to the bumpy, 3D texture of embroidery. This flat texture is what gives them their modern and sophisticated appearance. If you want a patch that feels premium and soft to the touch rather than rugged and thick, woven is the correct path.

How do I apply an iron-on woven patch?

Iron-on woven patches are applied using a commercial heat press or a household iron at a temperature of approximately 300°F (150°C) with firm pressure for 15-20 seconds. Because they are thinner than embroidered patches, the heat transfers through them very efficiently, creating a very strong and reliable bond with the garment.

Is there a limit to the number of colors I can use in a woven design?

While there is more flexibility than embroidery, we typically recommend keeping woven designs to 12 colors or fewer to maintain the structural integrity of the weave. However, because the threads are so fine, we can use "interweaving" techniques to create the illusion of even more shades and gradients.

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